A review on fabrication and characterization of WC–graphene self-lubricant tool prepared by spark plasma sintering

Purpose This review aims to address recent advancements in tungsten carbide (WC)–graphene self-lubricating cutting tool materials, with particular emphasis on the spark plasma sintering (SPS) fabrication process and the resulting microstructural, mechanical and tribological properties. Design/methodology/approach A comprehensive literature survey was conducted on WC–Co–graphene composites fabricated using SPS. This review analyzes the influence of the type and content of graphene, dispersion methods adopted and SPS processing parameters, such as sintering temperature, pressure and dwell time, on densification, grain growth and interfacial bonding. Microstructural characterization techniques and the mechanical and tribological properties reported in various studies were critically compared. Findings Recent studies have demonstrated that incorporating graphene, typically ranging from 0.05 to 0.15 Wt. %, significantly enhances densification, refines the grain size of WC and increase hardness, fracture toughness, thermal conductivity and wear resistance. Optimal sintering temperatures (1,350–1,550 °C) enable rapid densification while suppressing WC grain growth, whereas applied pressures of 50–80 MPa enhance particle rearrangement and interfacial bonding, and short dwell times of 3–10 min prevent the degradation of graphene. However, a higher graphene content often leads to agglomeration, increased porosity and deterioration of mechanical properties, highlighting the importance of optimizing the processing conditions. Originality/value This review offers a comprehensive analysis of WC–graphene self-lubricating tool materials produced via SPS. This review delineates the optimal graphene content, suitable processing conditions and primary challenges during the fabrication process. This insights information will assist researchers and tool manufacturers in developing high-performance cutting tools for dry and rapid machining applications.